Kohler KD36V16 User manual

Operation and Maintenance Manual
Translation of the original instructions
Diesel engine
KD36V16
From serial number 2017 17 0001
EN
33521029701_1_1
08-2018

Preface Operation and Maintenance Manual
Preface
Only for the United States of America:
WARNING:
This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
For more information go to www.p65warnings.ca.gov/.
WARNING:
Breathing diesel engine exhaust exposes you to chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area.
- If in an enclosed area, vent the exhaust to the outside.
- Do not modify or tamper with the exhaust system.
- Do not idle the engine except as necessary.
For more information go to www.p65warnings.ca.gov/diesel.
This Operating and Maintenance Manual has been written for the operator and
maintenance personnel of the Diesel engine.
It contains descriptions of the:
– Technical data
– Safety regulations
– Handling and operation
– Maintenance
Anyone involved in working with or on the Diesel engine must read and follow the
instructions in the Operating and Maintenance Manual carefully both before the
first commissioning and at regular intervals.
Work with the diesel engine includes:
–Handling
–Servicing, including maintenance, inspection.
The Service and Repair Manual facilitates the operator's familiarization with the
Diesel engine and prevents faults through incorrect operation.
Kohler Co. will not allow any warranty claims that arise due to incorrect operation,
insufficient maintenance, use of unapproved operating fluids or non-compliance
with safety regulations.
Kohler Co. will annul any obligations entered into by Kohler Co. and/or their
dealers such as warranty assurances, service agreements etc. without prior notice
if spare parts other than original Kohler parts or parts purchased from Kohler Co.
are used for maintenance and repairs.
2
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Preface
In extreme conditions, more frequent maintenance than scheduled in the
inspection plan can be required.
Changes, conditions, copyright
This document is protected by copyright. The copyright is held by:
– Kohler Co.
Subject to changes in the interests of technical progress.
Proprietary notice ISO 16016: “The reproduction, distribution and utilization of this
document as well as the communication of its contents to others without express
authorization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, utility model or
design.”
List of changes
Version from serial number Comments Date
33521029701_0_1 2017 17 0001 First version October 2017
33521029701_1_1 2017 17 0001 Various changes August 2018
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
3

Preface Operation and Maintenance Manual
4
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Contents
Service Assistance 9
1 Product description 11
1.1 Technical description 11
1.1.1 Design overview 11
1.1.2 Overview of sensors 14
1.1.3 Explanation of the type designation 14
1.2 Technical data 18
1.2.1 Diesel engine 18
1.2.2 Cylinder head 18
1.2.3 Coolant thermostat 18
1.2.4 Battery charging alternator 19
1.2.5 Starter 19
1.2.6 Flywheel housing 19
2 Safety 21
2.1 Identification of the warnings 21
2.2 Target audience 22
2.2.1 International standard classification of occupations 22
2.2.2 Occupational references 22
2.2.3 Unauthorized personnel 23
2.3 Intended use 24
2.4 Foreseeable misuse 24
2.5 General safety instructions 25
2.6 Preventing personal injuries 25
2.6.1 Bruises 25
2.6.2 Burns and scalding 26
2.6.3 Fires and explosions 26
2.6.4 Poisoning 26
2.6.5 High-pressure injection (liquids at high pressure can squirt out) 26
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
5

Contents Operation and Maintenance Manual
2.6.6 Electrical energy 27
2.6.7 Danger due to noise 27
2.7 Personal protective equipment 27
2.8 Operating areas and maintenance areas 28
2.8.1 Safety instructions 28
2.8.2 Operating areas 29
2.8.3 Maintenance areas 29
2.8.4 Secure and release the diesel engine against accidental starting 30
2.8.5 Emergency stop 31
2.8.6 Signage 31
2.9 Prevent material damages 32
3 Handling, operation 33
3.1 Start-up procedure 33
3.1.1 Filling the operating fluids 33
3.1.2 Starting the engine 33
4 Operating faults 35
4.1 Faults – Cause – Solution 35
5 Operating fluids and maintenance 41
5.1 Fill quantities 41
5.1.1 Lubricants and operating materials 41
5.2 Lubricants and operating materials 42
5.2.1 Diesel fuels 42
5.2.2 Engine oils 43
5.2.3 Coolant 45
5.3 Maintenance 47
5.3.1 Maintenance schedule 47
5.3.2 Daily, weekly and monthly maintenance work - Version: 2018/06-1 48
5.4 Maintenance schedule — ESP Fuel optimized 49
5.4.1 ESP Fuel optimized — Service level 1 - Version: 2018/06-1 49
5.4.2 ESP Fuel optimized — Service level 2 - Version: 2018/06-1 50
5.5 Maintenance schedule — ESP Emission optimized 51
5.5.1 ESP Emission optimized — Service level 1 - Version: 2018/06-1 51
6
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Contents
5.5.2 ESP Emission optimized — Service level 2 - Version: 2018/06-1 52
5.6 Maintenance schedule — ESP 50Hz emission optimized top power 53
5.6.1 ESP 50Hz emission optimized top power — Service level 1 - Version:
2018/06-1 53
5.6.2 ESP 50Hz emission optimized top power — Service level 2 - Version:
2018/06-1 54
5.7 Maintenance schedule — PRP Fuel optimized 55
5.7.1 PRP Fuel optimized — Service level 1 - Version: 2018/06-1 55
5.7.2 PRP Fuel optimized — Service level 2 - Version: 2018/06-1 56
5.8 Maintenance schedule — PRP Emission optimized 57
5.8.1 PRP Emission optimized — Service level 1 - Version: 2018/06-1 57
5.8.2 PRP Emission optimized — Service level 2 - Version: 2018/06-1 58
5.9 Maintenance schedule — COP Fuel optimized 59
5.9.1 COP Fuel optimized — Service level 1 - Version: 2018/06-1 59
5.9.2 COP Fuel optimized — Service level 2 - Version: 2018/06-1 60
5.10 Maintenance schedule — COP Emission optimized 61
5.10.1 COP Emission optimized — Service level 1 - Version: 2018/06-1 61
5.10.2 COP Emission optimized — Service level 2 - Version: 2018/06-1 62
5.11 Special tools for maintenance activities 63
5.12 Preparatory maintenance activities 64
5.13 Daily, weekly and monthly maintenance work 65
5.13.1 Perform visual inspection (leaks, damage, loose components) — SL000 65
5.13.2 Checking the engine oil level — SL001 67
5.13.3 Check coolant level — SL001 69
5.13.4 Check the ventilation holes on the water pump — SL003 70
5.13.5 Check/drain water trap on the primary fuel filter — SL004 70
5.14 Maintenance activities 72
5.14.1 Take oil sample and perform oil analysis — SL100 72
5.14.2 Replace diesel engine oil and oil filter — SL121 72
5.14.3 Replace the oil separator filter insert of the crankcase breather —
SL107 75
5.14.4 Replace main fuel filter — SL105 78
5.14.5 Replace the primary fuel filter — SL106 79
5.14.6 Take coolant sample and perform coolant analysis — SL120 79
5.14.7 Change air filter main element — SL108 80
5.14.8 Check state of fan drive belt drive and replace if necessary — SL118 80
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
7

Contents Operation and Maintenance Manual
5.14.9 Check and change the V-ribbed belt for the battery charging alternator
— SL109 83
6 Transport and storage 87
6.1 Fastening during transport 88
6.2 Wooden transport stand 90
6.3 Steel transport stand 91
6.4 Suspension device 92
6.5 Storage 94
6.6.1 Storage for up to 6 months 94
6.7.1 Storage for over 6 and up to 24 months 94
7.1 Standard torques 95
7.1.1 Standard torques for screw connections 95
7.1.2 Standard torques for screw plugs and hollow screws 96
7.1.3 Standard torques for flange joints 97
7.1.5 Metric flange joints, series L (light) for aluminum 100
7.1.6 Standard torques for cutting ring flange joints 101
7.1.7 Standard torques for Triple Lok® flange joints 101
7.1.8 Standard torques for VSTI screw plugs 102
7.2 Special tool 103
7.3 Terms used (glossary) 104
Index 105
8
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Service Assistance
Please contact your nearest Kohler Power Systems distributor or dealer for
professional advice on the generator set power requirements and conscientious
service.
For Kohler generating sets:
– Visit the web site of Kohler Co. at KOHLERPower.com.
– Pay attention to the labels and decals on your Kohler product or review the
appropriate literature or documents included with the product.
– In the USA and Canada, call toll-free 1-800-544-2444.
– Outside the USA and Canada, call the nearest regional office.
Headquarters in Europe, the Middle East and Africa (“EMEA”) India, Bangladesh, Sri Lanka
Kohler Power Systems Netherlands B.V. India Regional Office
Kristallaan 1 Bangalore, India
4761 ZC Zevenbergen Phone: [phone]
Netherlands (91) 80 3366231
Phone: [phone] Fax: [phone]
Fax: [phone]
Japan, Korea
Asia Pacific North Asia Regional Office
Kohler Asia Pacific Headquaters Tokyo, Japan
Singapore, Republic of Singapore Phone: [phone]
Phone: [phone] Fax: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
Tab. 1
To order special tools, please refer to the cross reference list in the annex.
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
9

Operation and Maintenance Manual
For KOHLER-SDMO power generating units:
– Visit the web site of KOHLER-SDMO at www.kohlersdmo.com.
– Pay attention to the labels and stickers on your KOHLER-SDMO product or
check the corresponding literature or documents included with the product's
scope of delivery.
– Call the nearest regional office.
SALES OFFICE FRANCE SOUTHWEST BRANCH OFFICES
WEST SDMO TOULOUSE SOUTH AFRICA
SDMO BREST TEL.: [phone] SDMO SOUTH AFRICA
TEL.: [phone] FAX: [phone] TEL.: [phone]
FAX: [phone]
SUBSIDIARIES
FAX: [phone]
MID-WEST GERMANY ALGERIA
SDMO CHOLET SDMO GMBH SDMO ALGIERS
TEL.: [phone] TEL.: [phone] TEL.: [phone]
FAX: [phone] FAX: [phone] FAX: [phone]
PARIS/NORTH & NORMANDY LATIN AMERICA & CARRIBEAN DUBAI
SDMO ARRAS TEL.: [phone] SDMO MIDDLE EAST
TEL.: [phone] FAX: [phone] TEL.: [phone]
FAX: [phone]
BELGIUM
FAX: [phone]
SDMO GENNEVILLIERS
TEL.: [phone] SDMO NV/SA EGYPT
FAX: [phone] TEL.: [phone] SDMO KAIRO
EAST FAX: [phone] TEL./FAX: [phone]
BRAZIL KENYASDMO METZ
TEL.: [phone] KOHLER MAQUIGERAL SDMO NAIROBI
FAX: [phone] TEL.: [phone] TEL./FAX: [phone]
SOUTHEAST SPAIN RUSSIA
SDMO AIX-EN-PROVENCE SDMO INDUSTRIES IBERICA SDMO MOSCOW
TEL.: [phone] TEL.: [phone] TEL.:/FAX: [phone]
FAX: [phone] FAX: [phone]
TOGOSDMO VALENCE
UNITED KINGDOMTEL.: [phone] SDMO WEST AFRICA
FAX: [phone] SDMO ENERGY LTD. TEL.: [phone]
TEL.: [phone]
TURKEYFAX: [phone]
To order special tools, please refer to the cross reference list SDMO ISTANBUL
in the annex. TEL.: [phone]
Tab. 2
10
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

1 Product description
1.1 Technical description
1.1.1 Design overview
This section contains an overview of the diesel engine with the names of the parts
shown.
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
11

Product description Operation and Maintenance Manual
Technical description
Fig. 1: Overview of flywheel side
1Intake stack 5Oil module 9Fastening point for turning
device
2Charge air line 6Battery charging alternator 10 Flywheel
3Pressure line rail 7Oil drain shut-off valve 11 Flywheel housing
4Engine control unit 8HP pump (two)
12
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description
Technical description
Fig. 2: Overview of power unit support side
1Coolant connection to coolant
cooling
4Exhaust gas turbocharger 7Coolant connection from
coolant cooling
2Charge air connecting line
from charge air cooler
5Oil filter 8V-ribbed fan belt
3Crankcase breather 6Main fuel filter
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
13

Product description Operation and Maintenance Manual
Technical description
1.1.2 Overview of sensors
Fig. 3: Overview of sensors
1Rotational speed sensor 4Temperature sensor 7Rotational speed sensor
2Service switch 5Pressure sensor
3Temperature sensor 6Temperature sensor
1.1.3 Explanation of the type designation
Type description
K D 36 V 16 - 5 A F C Engine type designation
K Manufacturer
D Diesel engine
36 Total displacement: 36 l
14
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description
Technical description
K D 36 V 16 - 5 A F C Engine type designation
V V-engine
16 No. of cylinders
5 Frequency: 5=50 Hz; 6=60 Hz
A Power level: A where A = the lowest power and E =
the highest power
F Optimization: F = Fuel Optimized; E = Emissions
Optimized
C Application: C = COP; P = Prime; S = Stand by; D =
Data center
Tab. 3
Diesel engine company nameplate
The Diesel engine company nameplate is mounted on the oil sump. A second
company nameplate is attached to the device.
Fig. 4: Company nameplate
Engine serial number
The engine serial number is stamped into the engine company nameplate and the
crankcase.
Fig. 5: Engine serial number
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
15

Product description Operation and Maintenance Manual
Technical description
2016 18 0001 Engine serial number
2017 Year of manufacture
17 Engine type code: 17= KD36V16
0001 Consecutive production number
Tab. 4
Engine control unit nameplate
Fig. 6: Position of the engine control unit nameplate
1Software nameplate
2Hardware nameplate
Fig. 7: Example of an engine control unit nameplate
1Delivery date 5Engine serial number
22D code bar 6Control unit ID number
3Engine type 7ID number certification
4Control unit description 8ID number parameter set
16
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description
Technical description
Note The information on the engine control unit
nameplate corresponds to the delivery status.
Depending on software updates in the field, this
information may no longer be up-to-date. The real
information can be viewed in the device display or
read out using the KODIA diagnosis and service
tool.
Tab. 5
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
17

Product description Operation and Maintenance Manual
Technical data
1.2 Technical data
1.2.1 Diesel engine
Description Unit Value
Design V-Diesel engine
No. of cylinders 16
Firing order according to DIN 73021 1-15-6-13-8-4-16-7-
11-5-9-2-14-10-3-12
Firing order according to ISO 1204 B10–A6–B7–A1–
B3–A4–B9–A8–B5–
A2–B1–A5–B4–
A10–B8–A7–B2–
A3–B6–A9
Bore mm
in
135
5.31
Stroke mm
in
157
6.18
Displacement l
gal
35,956
9.4986
Compression ratio 15 :1
Direction of rotation of the Diesel engine (seen
from flywheel)
Counterclockwise
Power specification as per ISO 3046–1
Rated power See company
nameplate
Rated speed See company
nameplate
Emission limit stage See engine
emissions
nameplate
1.2.2 Cylinder head
Description Unit Value
Inlet valve clearance, cold mm
in
0.5
0.019
Outlet valve clearance, cold mm
in
0.6
0.023
1.2.3 Coolant thermostat
Description Unit Value
Opening start °C 82
18
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description
Technical data
Description Unit Value
°F 179
Completely open °C
°F
92
197
1.2.4 Battery charging alternator
Description Unit Value
Voltage V 28
Current A 140
1.2.5 Starter
Description Unit Value
Voltage V 24
Output per start system kW 8.4
1.2.6 Flywheel housing
Description Unit Value
Connection SAE 0
KD36V16 33521029701_1_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
19

Product description Operation and Maintenance Manual
Technical data
20
© 2018 by Kohler Co. All rights reserved.
KD36V16 33521029701_1_1 en 2018-08-01